Pipe coupling for a venting system

ABSTRACT

A leak proof coupling is accomplished by the combination of the spreading of an end of a pipe and by the insertion of a silicone gasket over the female side of each pipe section. When the sections are put together, the gasket lip is deflected downward to a predetermined amount established by the dimensions of the joint. This deflection generates the compression required to seals the gap between the male and female sides of the coupling. Because of the choice of thickness of the gasket material in combination with the inside and outside diameter of the gasket, assembly of different components of the venting system with each other is facilitated without using special tools or fixtures. Disassembly of the same components for routine maintenance is also easier to accomplish with this coupling design.

The present patent application claims priority of U.S. 60/654,501 filed Feb. 22^(nd), 2005, the contents of which are incorporated herein by reference.

FIELD OF THE INVENTION

The present invention is directed to a ventilation system. More particularly, the present invention is directed to a pipe coupling for a pellet stove venting system.

DESCRIPTION OF THE PRIOR ART

Pellet stoves develop positive pressure inside the venting system. To prevent flue gases from escaping inside the building through the joint and pipe construction, it is absolutely critical that the pipe assembly be sealed. A number of solutions have been proposed, but none has been entirely satisfactory.

Prior art pipe assemblies have two major problems. The first problem is related to installation of the pipe assembly. Several pipe assemblies require sealant application in the field to make the assemblies leak proof which complicates their installation and causes difficulties when cleaning up after installation. Very often, the installer has to return to the installation site to verify that the sealant is still successfully applied. These pipe assemblies are also difficult to paint over.

The second problem of prior art systems is related to maintenance of the pipe assembly. Not only parts of the prior art systems are difficult to assemble, but they are equally difficult to disassemble when routine maintenance is required.

U.S. Pat. No. 6,026,803 by Wawrla discloses a coupling for use in venting systems which is self-sealing. The coupling comprises a mechanical locking device on a female part of the coupling to prevent disconnection of the male part therefrom. However, the coupling design does not stiffen the pipe in an efficient manner and does not guarantee maintenance of the roundness of the pipe under load stresses. The gasket is designed for low temperature exhaust gases applications and the single wall pipe construction/coupling will not allow close clearances to combustibles materials.

Thus there is presently a need for a pipe coupling system for venting systems that is easy to install and offers good stiffness and thermal properties.

SUMMARY OF THE INVENTION

An object of the present invention is to provide a pipe coupling for use in venting systems that addresses the above-mentioned needs.

More specifically, an object of the present invention is to provide a pipe coupling for components of a venting system comprising:

-   -   a male pipe member on an end of a first one of the components,         the male pipe member comprising a flue pipe having an outer         diameter at an outer end of the flue pipe;     -   a female pipe member on a corresponding end of a second one of         the components, the female pipe member receiving the male pipe         member and comprising:         -   a flue sleeve having variable inner diameters expanding in a             step-like manner from an inner end to an outer end of the             flue sleeve, a first of the inner diameters at the inner end             similarly sized with respect to the outer diameter of the             flue pipe, the flue sleeve having a second of the inner             diameters being sized larger than the outer diameter of the             flue pipe at the outer end;         -   an enlargement located proximate the outer end of the flue             sleeve; and         -   a compressible gasket held within the enlargement having an             inner diameter smaller than the outer diameter of the flue             pipe;             wherein the flue pipe remains in circumferential contact             with the compressible gasket when the male pipe member is             inserted into the female pipe member.

Another object of the present invention is to provide a venting system comprising components that are coupled with the coupling defined above.

Another object of the present invention is to provide a component of a venting system, the venting system having a flue pipe of a defined diameter, the component comprising:

-   -   a female pipe member on a first end of the component, the female         pipe member comprising:         -   a flue sleeve having variable inner diameters expanding in a             step-like manner from an inner end to an outer end of the             flue sleeve, a first of the inner diameters at the inner end             similarly sized with respect to the defined diameter of the             flue pipe, the flue sleeve having a second of the inner             diameters being sized larger than the defined diameter of             the flue pipe at the outer end;         -   an enlargement located proximate the outer end of the flue             sleeve; and         -   a compressible gasket held within the enlargement having an             inner diameter smaller than the defined diameter of the flue             pipe.

The present system offers several advantages including a leak proof coupling and pipe construction, a strong and durable design, an esthetically pleasant looking pipe, a faster and easier installation, an increased efficiency of the system and safer installation.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention and its advantages will be more easily understood after reading the following non-restrictive description of preferred embodiments thereof, made with reference to the following drawings in which:

FIG. 1 is a side partially cut view of a pipe coupling according to a preferred embodiment of the present invention;

FIG. 2 is a top view of a gasket according to a preferred embodiment of the present invention;

FIG. 3 is a side view of the gasket shown in FIG. 2;

FIG. 4 is a cross-sectional view of a portion of the gasket shown in FIG. 2;

FIG. 5 is a perspective view of a ventilation system linking a stove to an exterior of a building according to a preferred embodiment of the present invention;

FIG. 6 is a perspective view of a ventilation system linking a stove to an exterior of a building according to another preferred embodiment of the present invention;

FIG. 7 is a perspective view of a ventilation system linking a stove to an exterior of a building according to another preferred embodiment of the present invention;

FIG. 8 is a side partially cut view of a length to be used in a ventilation system according to another preferred embodiment of the present invention;

FIG. 9 is a side partially cut view of an adjustable length to be used in a ventilation system according to another preferred embodiment of the present invention;

FIG. 10 is a side partially cut view of a tee to be used in a ventilation system according to another preferred embodiment of the present invention;

FIG. 11 is a side partially cut view of a tee cap to be used in a ventilation system according to another preferred embodiment of the present invention;

FIG. 12 is a side partially cut view of a 45° elbow to be used in a ventilation system according to another preferred embodiment of the present invention;

FIG. 13 is a side partially cut view of a 90° elbow to be used in a ventilation system according to another preferred embodiment of the present invention;

FIG. 14 is a side partially cut view of an increaser to be used in a ventilation system according to another preferred embodiment of the present invention;

FIG. 15 is a side partially cut view of a stove adapter to be used in a ventilation system according to another preferred embodiment of the present invention;

FIG. 16 is a side partially cut view of a female flex adapter to be used in a ventilation system according to another preferred embodiment of the present invention;

FIG. 17 is a perspective view of a square support radiation shield to be used in a ventilation system according to another preferred embodiment of the present invention;

FIG. 18 is a top view of a ceiling support radiation shield to be used in a ventilation system according to another preferred embodiment of the present invention;

FIG. 19 is a side view of the ceiling support radiation shield shown in FIG. 18;

FIG. 20 is a top view of a ceiling support fire stop to be used in a ventilation system according to another preferred embodiment of the present invention;

FIG. 21 is a perspective view of a universal collar support to be used in a ventilation system according to another preferred embodiment of the present invention;

FIG. 22 is a perspective view of an adjustable wall support to be used in a ventilation system according to another preferred embodiment of the present invention;

FIG. 23 is a top view of a masonry adapter to be used in a ventilation system according to another preferred embodiment of the present invention;

FIG. 24 is a side view of a chimney adapter to be used in a ventilation system according to another preferred embodiment of the present invention;

FIG. 25 is a perspective exploded view of an adjustable wall thimble to be used in a ventilation system according to another preferred embodiment of the present invention;

FIG. 26 is a side view of a vertical rain cap to be used in a ventilation system according to another preferred embodiment of the present invention;

FIG. 27 is a side view of an adjustable rotational jet cap to be used in a ventilation system according to another preferred embodiment of the present invention;

FIG. 28 is a side view of a horizontal cap to be used in a ventilation system according to another preferred embodiment of the present invention;

FIG. 29 is a top view of a flashing to be used in a ventilation system according to another preferred embodiment of the present invention;

FIG. 30 is a side view of the flashing shown in FIG. 29;

FIG. 31 is a top view of a storm collar to be used in a ventilation system according to another preferred embodiment of the present invention;

FIG. 32 is a side view of the storm collar shown in FIG. 31 in a closed configuration.

FIG. 33 is a top view of a universal cap screen to be used in a ventilation system according to another preferred embodiment of the present invention; and

FIG. 34 is a side view of the universal cap screen shown in FIG. 33.

DESCRIPTION OF PREFERRED EMBODIMENTS

As shown in FIG. 1, the pipe coupling 10 according the present invention is to be used to join different components in various venting system applications. The pipe coupling 10 comprises a male pipe member 12 on an end of a first one of the components, the male pipe member 12 comprising a flue pipe 14 having an outer diameter at an outer end of the flue pipe 14. The coupling 10 further comprises a female pipe member 16 on a corresponding end of a second one of the components. The female pipe member 16 receives the male pipe member 12 and comprises a flue sleeve 18 having variable inner diameters expanding in a step-like manner from an inner end 20 to an outer end 22 of the flue sleeve 18. A first of the inner diameters at the inner end 20 is similarly sized with respect to the outer diameter of the flue pipe 14. The flue sleeve 18 also has a second inner diameter sized larger than the outer diameter of the flue pipe 14 at the outer end 22. The coupling 10 further comprises an enlargement 24 located proximate the outer end 22 of the flue sleeve 18. A compressible gasket 26 is held within the enlargement 24 and has an inner diameter smaller than the outer diameter of the flue pipe 14.

The flue pipe 14 remains in circumferential contact with the compressible gasket 26 when the male pipe member 12 is inserted into the female pipe member 16.

Preferably, the pipe coupling further comprises a male outer casing 28 surrounding at least a part of the male pipe member 12 and having a first outer casing circumference and a female outer casing 30 surrounding at least a part of the female pipe member 16 and having a second outer casing circumference. The first outer casing circumference is similar sized with respect to the second outer casing circumference.

Preferably, the end of the female outer casing 30 is sized smaller than the male outer casing 28 to facilitate the insertion of the male pipe member 12 into the female pipe member 16.

Preferably, the male outer casing 28 and the female outer casing 30 are sized such that the male outer casing 28 remains in contact with the female outer casing 30 when the male pipe member 12 is inserted into the female pipe member 16.

Preferably, the female pipe member 16 is attached to the flue sleeve 18 at the point of contact with the enlargement 24.

Preferably, the gasket 26 is made of one of silicone or rubber.

Preferably, as shown in FIGS. 2 to 4, the gasket 26 comprises an inwardly extending projection 32.

Preferably, the dimensions of the coupling combined with the dimensions and composition of the gasket will create enough pressure at contact points between the flue sleeve 18 and the flue pipe 14 to make a leak proof assembly.

Returning to FIG. 1, at least one fastener 34 preferably joins the male pipe member 12 to the female pipe member 16. According to a preferred embodiment of the present invention, the final section assembly is done by attaching each section together with three ¼″ long sheet metal screws.

In accordance with a preferred embodiment of the present invention, an object of the present invention is also to provide a venting system 40 comprising various components that are coupled with the coupling described hereinabove. FIGS. 5 to 7 illustrate three different venting system 40 configurations linked to pellet stoves 42.

Preferably, the system 40 of the invention consists of a number of components assembled together with the couplings 10 in a manner to vent flue gases to the outside of the building 44. The different components include, but are not restricted to the following: standard and adjustable lengths 46, elbows 48, tees 50, termination caps 52, floor, ceiling and wall shields 54, stove adapters 56, and supports 58, among others shown in FIGS. 5 to 7.

Different components to be used with the ventilation system are illustrated individually in FIGS. 8 to 32 and described below.

As shown in FIG. 8, the invention preferably provides lengths 60 that are preferably available in 48″, 24″, 18″, 12″ & 6″ lengths.

As shown in FIG. 9, the invention also preferably provides an adjustable length 62. This unique part enables an installer to adjust the system to the exact overall length required for any installation. The most common applications for the adjustable length 62 are:

-   -   Between elbows so that any required centre-to-centre offset can         be achieved.     -   When it is necessary to balance the chimney height so that the         caps line up for functional or aesthetic reasons.     -   When a specific horizontal offset is required.

The adjustable length 62 must be installed above a straight length. It will not adjust into an elbow or tee.

The flue pipe 14 diameter is smaller and the female outer casing 30 diameter is bigger than a regular coupling which enable the adjustable length to telescope into a regular straight length.

As shown in FIG. 10, the invention also preferably provides a tee 64. The tee can be used on the interior or exterior of the building.

As shown in FIG. 11, the invention also preferably provides a tee cap 66. The tee cap 66 incorporates the same silicone gasket 26 as the lengths as well as a handle 68 making it easy to remove for cleaning.

As shown in FIGS. 12 and 13, the invention also preferably provides 45° or 90° elbows 70, 72. The small radius of the elbows makes installations in tight spaces easier.

As shown in FIG. 14, the invention also preferably provides an increaser 74. The increaser 74 is designed to increase the diameter of a system to accommodate a range of flue sizes, appliances and installations.

As shown in FIG. 15, the invention also preferably provides a stove adapter 76. The stove adapter 76 fits both large OD flue collars (e.g.: Harman) and small OD flue collars. The stove adapter fastens permanently to the stove but can be easily disconnected from the rest of the vent to simplify cleaning.

In fact, the components illustrated in FIGS. 8 to 15 all incorporate silicone gaskets 26 making them easy to remove for cleaning.

As shown in FIG. 16, the invention also preferably provides a female flex adapter 78. The flex adapter provides a sealed connection where a flexible liner is installed above the venting system.

As shown in FIG. 17, the invention also preferably provides a square support/radiation shield 80. The square support/radiation shield 80 is rated to support up to 37′ (3″) or 30′ (4″) of venting where it passes through an insulated or un-insulated ceiling. It is particularly suitable for cathedral and drop ceilings. It is preferably supplied with a support collar.

As shown in FIGS. 18 and 19, the invention also preferably provides a ceiling support/radiation shield 82. The ceiling support/radiation shield 82 is rated to support up to 30′ (3″) or 25′ (4″) of venting where it passes through an insulated ceiling. It telescopes from 12″ to 23″ to keep insulation and debris away from the vent. It is preferably supplied with a support collar.

As shown in FIG. 20, the invention also preferably provides a support/fire stop 84. The support/fire stop 84 is rated to support up to 30′ (3″) or 25′ (4″) of venting where it passes through an un-insulated floor or ceiling. It is preferably supplied with a support collar.

As shown in FIGS. 21 and 22, the invention also preferably provides a universal support collar 86 and an adjustable wall support 88. The wall support is rated to support up to 21′ (3″) or 17′ (4″) of venting and fits 3″ and 4″ diameters. It adjusts easily to provide from 2″ to 5″ of clearance to the wall.

As shown in FIG. 23, the invention also preferably provides a masonry adapter 90. The masonry adapter 90 provides a tight, positive transition to a masonry chimney.

As shown in FIG. 24, the invention also preferably provides a chimney adapter 92. The chimney adapter 92 provides a positive sealed connection between the venting system and Class A chimneys by connecting 3″ or 4″ pellet vents to 6″, 7′ or 8″ Class A chimneys.

As shown in FIG. 25, the invention also preferably provides an adjustable wall thimble 94. The adjustable wall thimble 94 telescopes to accommodate wall thicknesses from 5″ to 10″. It is fully insulated to maintain insulation integrity and fits tightly to prevent air flow. The 3″ thimble requires a 6½″×6½″ framed opening; while the 4″ thimble requires a 7½″×7½″ framed opening.

As shown in FIG. 26, the invention also preferably provides a vertical rain cap 96.

As shown in FIG. 27, the invention also preferably provides an adjustable jet cap 98. The jet cap 98 can be rotated to direct hot flue gasses away from bushes or other things in proximity to the exhaust. The conical shape of the jet cap outlet will promote an increase in flue gasses exit velocity. The air space between the conical outlet and the base of the jet cap reduces the outlet back pressure caused by wind.

As shown in FIG. 28, the invention also preferably provides a horizontal cap 100. The horizontal cap 100 directs and accelerates flue gasses away from the house or building reducing the possibility of “moustache effect” from smoke accumulation.

As shown in FIGS. 29 and 30, the invention also preferably provides a flashing 102. These flashings 102 are made from either galvalume steel, which is considerably more corrosion resistant than galvanized, or from stainless steel for applications where maximum corrosion resistance is desired. They are made to cover the entire range of roof pitches.

As shown in FIGS. 29 and 30, the invention also preferably provides a storm collar 104. When the chimney passes through a radiation shield into an insulated space a storm collar 104 must also be installed to prevent the entry of insulation. A strom collar is also installed above the flashing to prevent the entry of rain water.

As shown in FIGS. 33 and 34, the invention also preferably provides a universal cap screen 106 to prevent the entry of birds and small animals into the venting system.

Preferably, the venting system further comprises an attic shield surrounding components of the venting system traversing a ceiling.

The leak proof coupling is accomplished by the combination of the spreading of pipe's end and by the insertion of a silicone gasket over the female side of each pipe section. When the sections are put together, the gasket lip 32 is deflected downward to a predetermined amount established by the dimensions of the joint. This deflection generates the compression required to seals the gap between the male and female sides of the coupling. Because of the choice of thickness of the gasket material in combination with the inside and outside diameter of the gasket, it is easy to assemble each piece of pipe together without using special tools or fixtures.

The gasket dimensions also ensure minimum friction between the gasket and the inner flue when the pipe expands and contracts with temperature. This design feature will increase the durability and life of the gasket.

The strong design is accomplished by the shape of the pipe's end. The inner flue is expanded in a multistep design that stiffens the pipe which keeps the roundness of the pipe under close tolerance even under load stress. This strength ensures that the gasket will almost always seal properly under every possible operating conditions. The outer casing is reduced in diameter at one end by 1¾″ which ensures a stable assembly. The final section assembly is done by attaching each section together with three ¼″ long sheet metal screws.

The outer casing design makes it possible to have a uniform and continuous surface which makes the assembly aesthetically pleasant looking. This is an important feature since the pipe can be apparent inside the building.

Because installers don't have to caulk each joint individually on site, the installation of a pellet venting system becomes faster with the present invention. Other features that make the installation faster and easier are the smallest wall opening in the industry for our wall pass-through and the adjustable wall support, the 2″ clearance to combustibles compares with 3″ from our competitors. The design of the plate opening for the wall pass-through and for the masonry chimney adapter also make the installation easier by sealing around the outer casing of the pipe and by incorporating support tabs to stabilize the venting system. The joint of the present invention is also free to rotate which makes it simpler to install in an offset installation.

The increased efficiency is done by the sealed air space between the inner flue and outer casing of the pipe. This is why we have a lower casing temperature and a smaller clearance to combustible materials. The rotational jet cap and the directional air flow of the horizontal cap make for a more efficient flue gases discharge. The flue gases are accelerated and directed away from the outside wall preventing staining.

The design of a cylindrical attic shield to prevent blown cellulose insulation from touching the outer casing of the vent make the system safer. No other pellet vent manufacturer supplies such a part.

Although the present invention has been explained hereinabove by way of a preferred embodiment thereof, it should be pointed out that any modifications to this preferred embodiment within the scope of the appended claims is not deemed to alter or change the nature and scope of the present invention. 

1. A pipe coupling for components of a venting system comprising: a male pipe member on an end of a first one of said, components, said male pipe member comprising a flue pipe having an outer diameter at an outer end of said flue pipe; a female pipe member on a corresponding end of a second one of said components, said female pipe member receiving the male pipe member and comprising: a flue sleeve having variable inner diameters expanding in a step-like manner from an inner end to an outer end of said flue sleeve, a first of said inner diameters at the inner end similarly sized with respect to the outer diameter of the flue pipe, said flue sleeve having a second of said inner diameters being sized larger than the outer diameter of the flue pipe at the outer end; an enlargement located proximate the outer end of the flue sleeve; and a compressible gasket held within the enlargement having an inner diameter smaller than the outer diameter of the flue pipe; wherein the flue pipe remains in circumferential contact with the compressible gasket when the male pipe member is inserted into the female pipe member.
 2. The pipe coupling according to claim 1, further comprising: a male outer casing surrounding at least a part of the male pipe member and having a first outer casing circumference; and a female outer casing surrounding at least a part of the female pipe member and having a second outer casing circumference, wherein the first outer casing circumference is similar sized with respect to the second outer casing circumference.
 3. The pipe coupling according to claim 2, wherein the male outer casing and the female outer casing are sized such that the male outer casing remains in contact with the female outer casing when the male pipe member is inserted into the female pipe member.
 4. The pipe coupling according to claim 1, wherein the gasket is made of one of silicone or rubber.
 5. The pipe coupling according to claim 1, wherein the gasket comprises an inwardly extending projection.
 6. The pipe coupling according to claim 1, further comprising at least one fastener joining the male pipe member to the female pipe member.
 7. The pipe coupling according to claim 4, wherein the gasket comprises an inwardly extending projection.
 8. The pipe coupling according to claim 7, further comprising at least one fastener joining the male pipe member to the female pipe member.
 9. A venting system comprising components that are coupled with the coupling defined in claim
 1. 10. The venting system according to claim 9, further comprising a fully rotational and configurable cap at an extremity of the venting system for redirecting a vented flue gas in a selected direction.
 11. The venting system according to claim 9, further comprising an attic shield surrounding components of the venting system traversing a ceiling.
 12. The venting system according to claim 9, wherein one of said components is selected from the group consisting of a stove adaptor, a standard length, an adjustable length, a tee, an elbow, and an increaser.
 13. A component of a venting system, said venting system having a flue pipe of a defined diameter, said component comprising: a female pipe member on a first end of said component, said female pipe member comprising: a flue sleeve having variable inner diameters expanding in a step-like manner from an inner end to an outer end of said flue sleeve, a first of said inner diameters at the inner end similarly sized with respect to the defined diameter of the flue pipe, said flue sleeve having a second of said inner diameters being sized larger than the defined diameter of the flue pipe at the outer end; an enlargement located proximate the outer end of the flue sleeve; and a compressible gasket held within the enlargement having an inner diameter smaller than the defined diameter of the flue pipe.
 14. The component according to claim 13, further comprising: a male pipe member on a second end of said component, said male pipe member being similarly sized with respect to the defined diameter of the flue pipe.
 15. The component according to claim 13, wherein the gasket is made of one of silicone or rubber.
 16. The component according to claim 13, wherein the gasket comprises an inwardly extending projection.
 17. The component according to claim 13, wherein the component is selected from the group consisting of a stove adaptor, a standard length, an adjustable length, a tee, an elbow, and an increaser.
 18. The component according to claim 14, wherein the component is selected from the group consisting of a standard length, an adjustable length, a tee, an elbow, and an increaser.
 19. The component according to claim 14, wherein the gasket is made of one of silicone or rubber.
 20. The component according to claim 19, wherein the gasket comprises an inwardly extending projection. 